Method of making channel forgings



' May 8, 1934. o. w. ANDERSON 1,958,178

METHOD OF MAKING CHANNEL FORGINGS 2 Sheets-Sheet 1 m A 11.. ,H,

Filed March 16, 1931 Patented May 8, 1934 METHOD OF MAKING CHANNEL FORGINGS Application March 16, 1931, Serial No. 523,120

Claims.

One of my objects, generally stated, is to provide a method of manufacturing channel-forgings whereby the side walls thereof may be caused to extend parallel with each other or in converging 5 relation, as desired, an example of such a forging having parallel side walls being the side-bearing of a railway car mounted on the truck and forming a channeled bearing member for a roller on which the car body is supported.

As forgings have hitherto been manufactured the requirement for draft on the male die results in the forming of the channel-forging with its side walls divergent and no provision has hitherto been made, so far as I am aware, for remedying this defect.

Another object is to provide improvements in the manufacture of channel forgings whereby in the forming of such structures distortion of the exterior corners of the forgings and of shoulders '20 or ribs when provided on the inner surfaces of their side walls, will not occur.

Another object is to avoid the objectionable formation of fillets at the inner surfaces of the junctures of the side walls of the forgings with the base portions thereof and which fillets interfere with the proper operations of the rollers seated in the channels when used as side bearings of railway cars; and other objects as will be manifest from the following description.

Referring to the accompanying drawings:

Figure l is a cross sectional view of a die which may be used in the practicing of the initial step of my improved method and which serves to forge the blank roughly to shape.

Figure 2 is a similar view of another form of die for use in the next stage of the operations for producing the finished channel forging.

Figure 3 is a similar View of still another die used in the forging operation and operating to flatten the web or bottom portion of the forging and roughly forge it to final shape and dimensions.

Figure i is a similar view of still another die to be used for finally shaping and gaging the web or base portion of the channel member and forging the side walls to definite angular position relative to the web or base.

Figure 5 is a similar View showing still another step in the producing of the finished channel forgmg.

Figure 6 is a View in side elevation of one form of a finished channel forging which may be produced by my method, certain steps in the performing of which are illustrated in the preceding figures.

Figure 7 is a View in longitudinal sectional elebeing formed of a base, or web, portion 10 and vation of the forging of Fig. 6, the section being taken at the line 7 on Fig. 8 and viewed in the direction of the arrow.

Figure 8 is a plan view of the forging; and

Figure 9, a section taken at the line 9 on Fig. 8 and viewed in the direction of the arrow.

I have illustrated the practicing of my improved method for the forming, by way of example, of a channel forging of the form shown in Figs. 6, 'l, 8 and 9 and constituting a channel-bearing of the kind above described, the channel-bearing shown side walls 11 rising therefrom the inner side surfaces 12 of which, between their ends, are parallel.

The base portion 10 is upwardly offset between its ends to present the portion represented at 13 and of convex shape at its lower surface as represented at 14 and of concave shape at its upper surface as represented at 15, with a transverse rib 16 at its underside located substantially midway between the ends of the forging, the concave portion 15 affording a bearing for a roller represented at 1'7 and guided by the parallel side walls 12.

The side walls 11 are inwardly deflected at their ends as represented at 18 and adjacent the junctures of these deflected portions with the parallel portions of the walls 11 are provided with up standing ribs 19 presenting curved surfaces 20 joining the ends of the concave bearing surface 15.

In the practicing of my improved method in accordance with the particular illustrated procedure, for forming the article above described, I provide a plurality of dies as represented in Figs.

Figs. 6-9, but with the web, or base portion 10 of th channel forging in upwardly deflected condition as shown in Fig. 1 and its side wall portions 11 widely diverging, the portions of the base portion 10 adjacent the side walls 11 extending at approximately right angles to these walls as shown and the interior corners of the forging being formed with grooves 24 extending the full length of the concave portion 15 and substantially the full length of the curved portions 20 of the forging and outwardly beyond the planes of the inner surfaces 25 of the side walls 11 and below the concave surface 15 of the base portion 10 and outwardly beyond the curved surfaces 20.

The forging produced by the dies 21 and 22 is then subjected to the dies 27 and 28 of Fig. 2 which operate to finish, as to shape and dimensions, all of the parts of the forging except the base portion 10 which latteris shaped to the form shown in this figure in which the portions of the base portion 10 adjacent the side walls 11 extend at approximately a right angle, preferably slightly in excess of a right angle thereto.

The forging is then subjected to the action of the dies of Fig. 3 and represented at 29 and 30 which operate merely to fiatten the curved base portion 10 and roughly forge the latter to final shape and dimensions in which operation the side walls ll swing into slightly divergent position sufficient to permit of ready withdrawal of the male die 30 from the forging.

The forging is then subjected to the action of the dies 31 and 32 of Fig. 4 which operate to forge the base portion 10 to final shape and dimensions and forge the side walls 11 to definite angular position relative to the base portion 10.

The grooves 24 formed in the forging in the operation illustrated in Fig. 1 are of such cross sectional area that, in the forging of the article to flatten its base portion 10, in which operation the metal of this portion of the forging at the inner surface of the channel is subjected to a compressing action, these grooves will not be entirely closed but will remain open as shown in Figs. 3 and 4 and thus the inner bottom surface of the forging when used as a side bearing for a car, either in the form shown in Fig. 4 or in the form shown in Fig. 5, will not present any raised portion engageable by an edge portion of the roller, but the roller engaging surface will be a plane surface in transverse section.

In this connection it will be noted that the forging of the plate into the condition shown in Figs. 1 and 2, namely, with its side walls 11 widely diverging, permits of the forging of the grooves 24 in the inner surfaces of the side walls 25, a feature of advantage in constructions of this character inasmuch as thereby the finished surface 15 of the bearing member may be provided of the maximum width, namely, of a width substantially equal to the distance between the side surfaces 25 of the walls 11 even when the male die becomes deformed, along its edges by continued use, thereby affording a bearing surface along which the roller travels, of a width equal to the thickness of the roller.

The feature of forming the base portion 10 with a deflected portion as shown in Fig. 1 and developed in Fig. 2, with the portions of the base portion 10 adjacent the side walls 11 extending at approximately right angles to the latter, is of advantage not only where the side walls of the finished forging are to be parallel or converge, but also where they are to diverge as shown in Fig. 4, inasmuch as the bending of the metal to position these side walls as stated occurs at portions of the base 10 set back from the junctures of the base with the side walls, as distinguished from the bending of the side walls to the desired position after the flat base portion has been formed and which would cause the comer edges of the base portion to be rounded.

When it is desired that the side walls of the forging extend parallel, or converge, the forging of Fig. 4, the side walls of which must be divergent to permit the same to be removed from the forging, is subjected to the action of the dies of Fig. 5

which comprise a female die 33 having a die cavity 34 of a contour corresponding with the exterior contour of a side wall 11 and the base portion 10 of the forging of Fig. 4, and a male die 35 the surfaces 36 and 37 of which are of a contour corresponding with the internal contour of one of the side walls 11 and the base portion 10, the male die being of less width than the width of the channel of the finished forging.

When the inner side walls 11 of the forging are to extend in the finished structure at right angles to the base portion 10, the converging walls of the cavity 34 would extend at a right angle to each other and likewise the surfaces 36 and 37 of the male die 35. Thus when these die members operate on the forging the side wall 11 and base portion 10 are forged to right angled condition,

it being understood that after forging one side wall 11 to the position stated the forging is reversed on the die 35 to forge the other side wall 11 to the position stated in the next forging operation.

It will also be understood that the side walls 11 may be forged to converging position, if desired, by forming the walls of the cavity 34 and the effective die surfaces of the die 35, to extend at an angle less than a right angle and corresponding with the acute angle at which the side walls 11 are to extend relative to the base portion 10 in the finished forging.

While I have illustrated and described a particular way of practicing my improved method and have shown my invention as embodied in a certain particular structure, I do not wish to be understood as intending to limit it thereto as my improved method may be practiced in many other ways and the structure shown may be variously modified and altered without departing from the spirit of my invention.

What I claim as new, and desire to secure by Letters Patent, is:

1. The method of producing channel forgings, which comprises forging the material from which the forging is to be made into a condition in which its side walls extend in diverging condition and its base portion is in inwardly deflected condition and inner surfaces of said side walls and base portion present grooves at the juncture of said Walls and base portion, and thereafter exerting a flattening action on said base portion and in such action permitting said side walls to move toward parallelism.

2. The method of producing channel forgings, which comprises forging the material from which the forging is to be made into a condition in which its side walls extend in diverging condition and its base portion is in inwardly deflected condition, with the portions of said base portion adjacent said side walls disposed at substantially a right angle to said side walls, and inner surfaces of said side walls and base portion presentgrooves at the junctures of said walls and base portion, and thereafter exerting a flattening action on said base portion and in such action permitting said side walls to move toward parallelism.

3. The method of producing channel forgings, which comprises forging the material from which the forging is to be made into a condition in which its side walls extend in diverging condition and its base portion is in inwardly deflected condition and inner surfaces of said side walls present grooves at the juncture of said walls and base portion, and thereafter exerting a flattening action on said base portion and in such action permitting said side walls to move toward parallelisri.

e. The method of producing channel forgings, which comprises forging the material from which the forging is to be made into a condition in whi h its side walls extend in diverging condition and its base portion is in inwardly deflected condition inner surfaces of said side walls pres at the juncture of said walls and tion extending downwardly to points not i i ban the plane of the inner surface of said case portion, and thereafter exerting a flattenilg actic on said base portion and in such action p rmitting said side walls to move toward method of producing channel forgings, ises forging the material from which id base portion is in inwardly deflected ion, with the portions of said base portion acent side walls disposed at substantially a right angle to said side walls, and inner surfaces of side walls present grooves at the junctures of said walls and base portion, and thereafter exerting flattening action on said base portion and in such action permitting said side walls to move toward parallelism.

The method of producing channel forgings, W1 ch comprises forging the material from which the urging is to be made into a condition in which its side walls extend in diverging condition and its base portion is in inwardly deflected condition, with the portions of said base portion adjacent said side walls disposed at substantially a right ngie to said side walls, and inner surfaces of said side walls presenting grooves at the junctures of said walls and base portion extending downward- 1y to points not higher than the plane of the inner surface of said base member, and thereafter e rting a flattening action on said base portion an in such action permitting said side walls to move toward parallelism.

7. The method of producing channel forgings which coin forming a base portion to inwardly ClEfi8cJl position with side walls diverging outwardly from the edges thereof and with grooves at the juncture of the side walls and the edges of the base portion extending outwardly from the inner surfaces of said side walls, and flattening the inwardly deflected portion of said base thereby causing the side walls to approach parallelism, said grooves insuring against the forming of fillets at the interior angles between said base portion and side walls.

8. The method of producing channel forgings which comprises, forming a base portion to inwardly deflected position with side walls diverging outwardly from the edges thereof and with grooves at the juncture of said side walls and the edges of the base portion extending outwardly from the inner surface of both said side walls and base portion, and flattening the inwardly deflected portion of said base thereby causing the side walls to approach parallelism, said grooves insuring against the forming of fillets at the interior angles between said base portion and side walls.

9. The method of producing channel forgings which comprises: forming a base portion to inwardly deflected position with side walls diverging outwardly from the edges thereof and with grooves at the juncture of the side walls and the edges of the base portion extending outwardly from the inner surface of said side walls; flattening the inwardly deflected portion of said base thereby causing the side walls to approach parallelism; and finally successively bringing the side walls truly to the desired angle of not more than 90 to the said base portion.

10. The method of producing channel forgings which comprises: forming a base portion to inwardly deflected position with side walls diverging outwardly from the edges thereof and with grooves at the juncture of the said side walls and the edges of the base portion extending outwardly from the inner surface or" both said side walls and base portion; flattening the inwardly deflected portion of said base thereby causing the side walls to approach parallelism; and finally successively bringing the side walls truly to the desired angle of not more than 90 to the said base portion.

OSCAR W. ANDERSEN. 

